Electrical outlet box

ABSTRACT

An electrical outlet box assembly provides for the accommodation of dual voltage fixtures. The outlet box assembly accommodates electrical fixtures and data fixtures along separate mounting axes. The electrical outlet box assembly provides for increased capacity while meeting applicable code requirements.

[0001] The present application claims priority to provisionalapplication No. 60/272,129, filed Feb. 28, 2001, and entitled “IMPROVEDELECTRICAL OUTLET BOX”.

FIELD OF THE INVENTION

[0002] The present invention relates generally to an electrical outletbox for housing electrical fixtures such as a switch or a receptacle.More particularly, the present invention relates to an improvedelectrical outlet box providing for the accommodation of dual voltagefixtures.

BACKGROUND OF THE INVENTION

[0003] It has long been known to house electrical fixtures such asswitches and receptacles in an electrical outlet box. The outlet boxpermits the insertion of electrical wires into the box which areterminated to electrical fixtures. The fixtures then may be mounted tothe box which provides protection to the fixtures as well as the wiresterminated therein. The outlet box is then mounted to a wall stud at aconvenient location to provide access. Most outlet boxes accommodate oneor more electrical fixtures which terminate standard 110 volt electricalwires.

[0004] It has also become necessary to terminate communications wiresfor such purposes as data, voice and signal transmission. Whileterminations are not required to be housed in an electrical box, as areelectrical terminations such as switch and receptacles, aesthetics andconvenient usage has dictated the need to place the communicationterminations in close proximity to the electrical terminations.

[0005] The art has developed various boxes and housing which provide forboth the accommodation of electrical terminations as well ascommunication terminations. Examples of outlet boxes which houseelectrical terminations and also support communication terminations areshown, for example, in U.S. Pat. Nos. 5,354,953; 5,646,371; and5,598,998. As seen in these patents, the electrical termination isseparated from the communications terminations by a solid wall.Typically, this wall is formed by the outside wall of the box whichhouses the electrical terminations where the electrical terminations areheld inboard of the outlet box and the communications terminations aresupported outboard of the outlet box.

[0006] Common practices and the need to use standard uniform componentsto cover the outlet box and provide for the ability to readilyinterconnect to the terminated wires requires that the distance betweenthe electrical termination and the communications termination be fixed.Also, relevant electrical codes dictate the minimum distance that thereceptacle need be spaced from the side walls of the outlet box. In theelectrical outlet boxes, the art has seen the need to increase the totalinterior capacity of the box so as to accommodate larger numbers ofwires and terminations. With respect to dual voltage boxes, it hasbecome difficult to simultaneously increase the usable interior space ofthe electrical outlet box while maintaining proper spacing between theelectrical termination and the communications termination. Attempts toadjust the receptacle within outlet box may result in the receptaclebeing positioned either too close to one of the side walls or outsidethe required distance from the communications termination.

[0007] It is, therefore, desirable to provide electrical outlet boxwhich provides increased capacity meets applicable code requirements andwhich is capable of accommodating dual voltage terminations.

SUMMARY OF THE INVENTION

[0008] The present invention relates to a single gang electrical outletbox assembly for accommodating a single electrical fixture such as aswitch or receptacle. The outlet box assembly also provides forsupporting a communication fixture such as a data plug. The outlet boxassembly has a generally rectangular electrical box having a first sidewall spaced apart from a second side wall. The pair of spaced apart sidewalls define a first mounting axis therebetween, the first mounting axisbeing generally parallel to the first and second side walls and providesfor mounting an electrical fixture thereon. A supporting structure foraccommodating a communication fixture extends from the first side walland possesses a second mounting axis which is generally parallel to thefirst side wall. The first mounting axis for the electrical fixture andthe second mounting axis for a communication fixture are substantiallyequidistant from a center line of the first side wall. The firstmounting axis is closer to the first side wall than to the second sidewall.

[0009] The present invention also provides for a multigang outlet boxassembly for accommodating plural electrical fixtures such as switchesand/or receptacles and also for supporting a communication fixture suchas a data plug. The multigang outlet box assembly has a generallyrectangular electrical box having a first side wall spaced apart from asecond side wall. The pair of spaced apart side walls supports anelectrical fixture therebetween, the fixture being mounted on a firstmounting axis adjacent the first sidewall. The rectangular electricalbox of the multigang outlet box also provides for a second electricalfixture mounting axis adjacent the second side wall. Both the first andsecond mounting axes are generally parallel to the first and second sidewalls. A support structure extends externally from the first side wallof the rectangular electrical box. The support structure is used foraccommodating a communication fixture along a third mounting axis, thethird mounting axis being generally parallel to the first side wall. Thefirst and third mounting axes are substantially equidistant from acenter line of the first side wall. The first mounting access is closerto the first side wall than the second mounting axis is to the secondside wall.

[0010] The present invention further provides for a single electricalgang outlet box for accommodating an electrical fixture such as aswitch, receptacle or the like. The box has a generally rectangularhousing having a back wall, a perimetrical side wall extending from saidback wall, and an open front face. The back wall, perimetrical sidewall, and open front face define a box interior for accommodating afixture. The perimetrical side wall includes top and bottom walls andopposed side walls. Each of the top and bottom walls includes mountingmembers for securing a fixture to the housing. The mounting members arealigned along an axis generally parallel to the side walls. Thismounting axis is closer to one of the side walls than to the other sidewall for off-center mounting of the fixture in the housing interior.

[0011] The present invention still further provides for a single gangelectrical outlet box assembly for supporting an electrical fixture anda communication fixture. The electrical fixture may be a switch or areceptacle or the like and the communication fixture may be a plug suchas a data plug, coaxial connector, or a fiber optic connector. Theoutlet box has a box interior defined between a first side wall and asecond side wall for supporting an electrical fixture within the boxinterior. A support structure extends from the first side wall foraccommodating the communication fixture. The outlet box includeselectrical fixture mounting members spaced apart along a first axisbetween and generally parallel to the first and second side walls. Thesupport structure includes communication fixture mounting members spacedapart along a second axis. The second axis is also parallel to the sidewalls. The first and second axes are generally equidistant from thefirst side wall. The first axis, however, is non-centrally locatedbetween the first and second side walls.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a front perspective view of the dual voltage electricaloutlet box of the present invention.

[0013]FIG. 2 is a front plan view of the dual voltage box of FIG. 1.

[0014]FIG. 3 is a side elevational showing of the dual voltage box ofFIG. 1.

[0015]FIG. 4 is rear perspective showing of the dual voltage outlet boxof FIG. 1.

[0016]FIGS. 5 and 6 are schematic representations of single gang andmultiple gang outlet box of the present invention.

[0017]FIG. 7 is a schematic of a single gang outlet box showing certaindimensions standardized by the National Electric Code.

[0018]FIG. 8 is a schematic of a multiple gang outlet box showingcertain dimensions standardized by the National Electric Code.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] The dual voltage electrical outlet box assembly 10 of the presentinvention provides for the accommodation of both electrical fixtures(not shown) such as switches or receptacles and a communication fixture(not shown) such as data plugs, coaxial connectors, fiber opticconnectors and the like which provide for termination of voice, data orsignal wires.

[0020] Outlet box assembly 10 may be formed of a wide variety ofmaterials as is well known in the art. In the particular example shownherein, box assembly 10 is formed of integrally molded plastic. Boxassembly 10 includes an electrical outlet box 12 which is generally arectangular member having a back wall 14, a pair spaced apart side walls16 extending from back wall 14, and opposed top and bottom walls 18 and20. Back wall 14, side walls 16 and top and bottom walls 18 and 20 forma box interior 22 having an open front face 24 which accommodatestherein an electrical fixture.

[0021] As is well known in the art, outlet box 12 may include one ormore access openings 26 which permit entry of electrical wires andcables (not shown) into box interior 22. The exterior surfaces of topand bottom walls 18 and 20 may include mounting flanges 28 which allowthe box to be secured to a building stud or the like in conventionfashion by use of a fastener such as a nail or screw. Top and bottomwalls 18 and 20 include opposed inwardly directed mounting elements 30each having a central screw threaded aperture 32 therethrough. Themounting elements 30 permit the attachment of electrical fixtures withinthe interior 22 of box 12 in convention fashion. The location ofmounting elements 30 and the screw threaded aperture 32 will bedescribed in further detail hereinbelow.

[0022] Box assembly 10 further includes an externally supported frame 40attached to one side wall 16 of box 12. Frame 40 is generallyrectangular and is positioned in flush relationship with the open frontface 24 of box 12. Frame 40 includes opposed upper and lower spacedapart legs 42 and 44 and a joining strut 46 extending between the distalends of legs 42 and 44. The upper and lower legs 42 and 44 along withstrut 46 and adjacent side walls 16 of box 12 define the rectangularframe 40. The upper and lower legs 42 and 44 of frame 40 includemounting elements 48 which are inwardly directed and include screwthreaded apertures 49. The mounting elements 48 and screw threadedapertures 49 permit accommodation of a face plate (not shown) whichsupports a communications termination device generally centrally locatedwithin frame 40.

[0023] Side walls 16 further include outwardly directed cable holdingflanges 50 and 52 which extend within the interior defined by frame 40.Cable holding flanges 50 and 52 are designed to accommodate and supportcommunications wires prior to termination to the communicationterminations. Also, strut 46 supports a pair of outwardly extending tabs55 for supporting the wallboard within which assembly 12 is positioned.

[0024] The manner in which box assembly 10 support electricaltermination devices as well as communication termination devices and theability to support an appropriate cover thereover is shown in furtherdetail in U.S. Pat. No. 5,354,953, issued Oct. 11, 1994, and entitled“Cable Holding Device”, the disclosure of which is incorporated hereinfor all purposes. As is particularly shown in the '953 patent, the plateplaced over the outlet box provides access to a duplex receptacle aswell as a data jack. As a conventional cover is placed thereover, thecenter line of the duplex connector as well as the center line of thedata plug must be spaced apart a fixed distance. Furthermore, withregard to the outlet box portion 12 of box assembly 10, certain distancerequirements are dictated by applicable codes. These distances are shownin FIG. 7 with respect to a single gang box and in FIG. 8 with respectto a multiple gang outlet box.

[0025] Referring now to FIG. 5, the ability of the present invention toprovide an outlet box assembly 10 for accommodating electrical fixturesso that the outlet box has an extended capacity, yet meet theconventional requirements dictated by applicable codes and accommodatethe conventional requirements of power/communication terminations areshown schematically with respect to FIG. 5.

[0026] Box 12 is represented by the left-hand rectangle while frame 40is represented by the right-hand rectangle. The arrangement of themounting elements 30 of box 12 and mounting elements 48 of frame 40 issuch that vertical mounting axes and x₁ and x₂ are defined. The distancebetween the mounting axes denoted as a₃ is fixed based upon therequirements of components such as cover plates which must be placedover the mounted electrical fixtures as well as the communicationfixtures. In order to provide an expanded interior for box 12, mountingaxis x₁ of box 12 is positioned closer to common wall 16 a than theopposed side wall 16 b. Thus, as shown in FIG. 5, a₁ is less than b.However, as required by the dictates of, for example, the cover plate,common wall 16 b must be equidistant between both mounting axes x₁ andx₂ such that a, is equal to a₂, and a₁+a₂=a₃. Common wall 16 b isdefined as being generally equidistant between the mounting axes x₁ andx₂. However, as may be appreciated, the common wall 16 b has a certainthickness. Manufacturing tolerances may be such that due to variationsin the thickness of the wall, one surface of the wall may be closer toone of the axes than the other surface is to its adjacent axis. However,absent such manufacturing tolerances, the present invention provides forthe common wall to be generally equidistant between the two mountingaxes. As used herein throughout, the phrase “generally equal” or“generally or substantially equidistant” takes into consideration suchmanufacturing tolerances.

[0027] The axes x₁ and x₂ must be maintained at a certain minimumdistance from common wall 16 a. Axis x₁ must also be a fixed distancefrom axis x₂. Therefore, increased interior volume of box 12 isaccommodated by extending the distance between axis x₁ and the oppositeside wall 16 b. Thus, axis x₁ and, therefore, the mounting apertureswhich define the axis, is off-centered with respect to box 12, the axisbeing closer to one side wall than the side wall.

[0028] Referring now to FIG. 6, the present invention may be practicedin a multi-gang box configuration. A multi-gang box assembly 10′includes an outlet box 12′ and frame 40′. Box 12′ accommodates twoelectrical fixtures and is defined by a pair of side walls 16 a′ and 16b′. As with the embodiment of FIG. 5, mounting axes y₁ and y₂ aredefined for mounting a pair of electrical fixtures. Frame 40′ is definedby the right-hand rectangle outboard of side wall 16 a′. A mounting axisy₃ is defined with frame 40. As with the embodiment of FIG. 5, side wall16 a′ is located substantially equidistant between mounting axes y₁ andy₃. In order to provide extra capacity for box 12′, mounting axis Y₂ ispositioned so that its distance d₄ from its adjacent side wall 16 b′ isgreater than d₂, the distance of mounting axis y₁ from its respectiveside wall 16 a′.

[0029] Having described the particular embodiments of the inventionherein, it should be appreciated that modifications may be made theretowithout departing from the contemplated scope of the invention.Accordingly, the embodiments described herein are intended to beillustrative rather than limiting, the true scope of the invention beingset forth in the claims appended hereto.

What is claimed is:
 1. A single gang electrical outlet box assembly foraccommodating a single electrical fixture and for supporting acommunication fixture, said assembly comprising: a generally rectangularelectrical box having a first side wall spaced apart from a second sidewall, said first and second side walls defining a first mounting axistherebetween generally parallel to said side walls for mounting saidelectrical fixture; and a supporting structure extending from said firstside wall for accommodating a communication fixture along a secondmounting axis generally parallel to said first side wall; said first andsecond mounting axes being substantially equidistant from a centerlineof said first side wall, with said first mounting axis being closer tosaid first side wall than said second side wall.
 2. An outlet boxaccording to claim 1 wherein said electrical box further comprises aback wall extending between said first and second side walls.
 3. Anoutlet box according to claim 2 wherein said electrical box furthercomprises a top wall and a bottom wall connecting said first and secondside walls.
 4. An outlet box according to claim 2 wherein said back wallfurther includes access openings adjacent said first and second sidewalls.
 5. An outlet box according to claim 3 wherein said top and bottomwalls further include mounting flanges on an exterior surface of saidtop and bottom walls.
 6. An outlet box according to claim 1 wherein saidelectrical fixture is selected from the group consisting of switches andreceptacles.
 7. An outlet box according to claim 1 wherein saidcommunication fixture is selected from the group consisting of dataplugs, coaxial connector, and fiber optic connectors.
 8. An outlet boxaccording to claim 1 wherein said supporting structure further comprisesan upper leg spaced apart from a lower leg, said upper and lower legsconnecting said first side wall to a joining strut extending betweendistal ends of said upper and lower legs.
 9. An outlet box assemblyaccording to claim 8 wherein said upper and lower legs further comprisemounting elements located along said second mounting access.
 10. Anoutlet box according to claim 1 wherein said first side wall furthercomprises cable holding flanges.
 11. A multigang outlet box assembly foraccommodating plural electrical fixtures and for supporting acommunication fixture, said assembly comprising: a generally rectangularelectrical box having a first side wall spaced apart from a second sidewall for supporting said fixtures therebetween, said electrical boxdefining a first electrical fixture mounting axis adjacent said firstside wall and a second electrical fixture mounting axis adjacent saidsecond side wall, each of said fixture mounting axes being generallyparallel to said side walls; and a support structure external of saidfirst side wall for accommodating a communication fixture along a thirdmounting axis generally parallel to said first side wall; said first andthird mounting axis being substantially equidistant from a central lineof said first side wall, with said first mounting axis being closer tosaid first side wall than said second mounting axis is to said secondside wall.
 12. A multigang outlet box assembly according to claim 11,wherein said electrical box further comprises a back wall extendingbetween said first and second side walls.
 13. A multigang box accordingto claim 12, wherein said back wall further comprises a top wall and abottom wall connecting said first and second side walls.
 14. A multigangbox according to claim 12, wherein said back wall further includesaccess openings adjacent said first and second side walls.
 15. Amultigang box according to claim 13, wherein said top and bottom wallsfurther including mounting flanges on an exterior surface of said topand bottom walls.
 16. A multigang box according to claim 11, whereinsaid electrical fixture is selected from the group consisting ofswitches and receptacles.
 17. A multigang outlet box according to claim11, wherein said communication fixture is selected from the groupconsisting of data plugs, coaxial connector, and fiber optic connectors.18. A single electrical gang outlet box for accommodating an electricalfixture, said box comprising: a generally rectangular housing having aback wall, a perimetrical side wall extending from said back wall and anopen front face defining a box interior for accommodating said fixture;said perimetrical wall including opposed top and bottom walls andopposed side walls; each of said top and bottom walls including mountingmembers for securing said fixture to said housing, said mounting membersbeing aligned along an axis generally parallel to said side walls withsaid axis being closer to one of said side walls than to the other sidewall for off-center mounting of said fixture in said housing interior.19. A single gang electrical outlet box assembly for supporting anelectrical fixture and a communication fixture, said assemblycomprising: an electrical outlet box having a box interior definedbetween a first side wall and a second side wall for supporting saidelectrical fixture within said interior; and a support structureextending from said first side wall for accommodating said communicationfixture; said outlet box including electrical fixture mounting membersbeing spaced apart along a first axis between and generally parallel tosaid first and second side walls; said support structure includingcommunication fixture mounting members being spaced apart along a secondaxis exterior and generally parallel to said first side wall; said firstand second axes being generally equidistant from said first side wall;said first axis being non-centrally located between said first andsecond side walls.